Spring cushion construction



Sept. 4, 1934. W B` FOSTER 1,972,397

SPRING CUSHION CONSTRUCTION Filed Oct. 9, 1933 2 Sheets-Sheet l zo 40 '2h "fsf 'Ik if INVENTOR wimam Foster Q MVM/ ATTORN EYS Sept. 4, 1934.

w. B. FOSTER SPRING CUSHION CONSTRUCTION Filed Oct. 9. 1935 2 Sheets-Sheet 2 mmw ATTORNEY Patented Sept. 4, 1934 PATENT OFFICE SPRING CUSHION CONSTRUCTION William BfFoster, Utica, N. Y., assignor to Foster Brothers Manufacturing Company, Utica, N. Y.,

a corporation' of New York i Application October 9, 1933, Serial No. 692,722

- p 4 Claims. (CI. 5 309) This invention relates to a spring cushion construction and particularly to a springcushion having a silencer pad mounted on the springs ins termediate their ends and to the silencer pad [therefor and to the .process of making the pad and mounting it on a set of springs to .form a complete construction. 1 f y The purposes of my .present invention are to provide a new and improvedspring cushion oonstruction and one that canbe'easily and economically manufactured orassembled` and'thatis effective in eliminating noise from the metal springs and remains noiseless after'long use; `to provide a new and improved form ofsilencing pad lf especially adapted -to be readily -mounted upon a set of springs and to remain in position therein without the use of further fastening means and generally to point out the process of making such a spring cushionconstruction and the silencing pad therefor. f,

Further objects and advantages will appear from the specification and claims herein.

Figs. 1, 2 and 3 areplan viewsof the topfor bottom of parts of three forms of silencing pads that may be used in constructions embodying this invention. s

Fig.V 4 is a plan view-of part of a silencing strip especially adapted torbe used to make -such-.si-

lencing pads, parts o'f the top layer of fabrican'd' of the fibrous filling being removed'to more clearly show the construction. Y

of a portion of a spring cushion construction emform illustrated in Figjl.-

Fig. 6 is a transverse Vsectional View on line 6-6 of Fig. 5 but on anenlarged scale. 1- 'f Fig. 7 is a perspective lviewof part-'of such ay cushion. j Y n p Fig. 8 is a diagrammatic view in s'ide'elevation of a device for forming the'silencing: strips. Fig. 9 is a plan view similar to Fig. 1 o f a modi-V fied form of pad.

Fig. 10 is a plan view of a construction embodying my invention adaptedvto achair seat or vthe like where the springs are not arranged in regu-` lar longitudinal'and transverse rows.

description it will be seenthat a springc'ushion 5 construction embodying this 'invention comprises a set of springs 10 arranged in rows longitudinally and also preferably transverselywith means .'11

connecting the Vend coils of- .adjacent springs and 'bodymg my mventlonthe padshowp ,bemg O-fohe. side .elevation ofA a convenient device forform- 90 a silencing or sound-deadening'l'pad :12 arranged midwayV the length of, or intermediate the ends of, the springs 10.

The silencing pad 12 isof the length and Width of the spring cushion and is mounted upon the springs and loosely butsecurely. held in place 6o intermediate the length of the springs by being provided' with slits 13 extending completely through the pad, one ofsaidslits being provided for each spring in the spring cushion and said slits being arranged in rows longitudinally and usually transversely of the pad so that each slit will be positioned substantially diametrically of the circle of its spring. v

My preferred form of pad and my preferred method of making such slitted .silencing pad is to build up a complete pad out of a plurality of silencing strips 17 with said strips arranged side by side and with theadjacent strips fastened together at spaced intervals, leaving between said fastenings the said slits. .Conveniently and prefv erably also the said silencing stripsv are composite, being formed of a layer of fibrous packing secured between two layers of fabric. This practice allows of forming the silencing strips out of cheap'material such as a filling or packing of 80 iibrousmaterial 14 secured between two layers of fabric as layers 15 and 16 of cloth.

Between the upper fabric layer 15 and the lower fabric layer 16 is placed a length of the fibrous lling 14 such as cotton or the like and these 85 three layers are suitably fastened together near Fig 5 is a top View (with parts brokenaway). the two side edges as by seams 18 of stitches.

There is thus formed a silencing strip 17 as shown in Fig. 4. Fig.,8 shows a diagrammatic View in ing these silencing strips 17 in long lengths by drawing cloth fromupper clothfroll 19 and fromv lower cloth roll 20 andviibrous filling from a large roll 21. As the three layers are drawn forward with thefibrous lling between the two layers of fabric thesewing machine 22 with its two needles 22a-and22b makes the edge seams 18 of stitches connecting rall three layers. This long-strip is then cut transversely into suitable lengths to make the silencing strip 17. In the samevor anv equivalent way half width silencingrstrips 23 are made having their three layers of material fasv tenedtogether by rows of stitches 24 nearrthe Referring to the drawingsin amore particular.

opposite side edges. Y p

Al silencing pad 12 is made. up by taking the 105 Vproper numberof full width silencing strips 1'? intended tofbe used with a set of'springs having 119 n ve longitudinal rows of springs. It will be seen that this pad is formed of four of the full width silencing strips 17 and two of the half width silencing strips 23. This set of strips is placed side by side with the narrow strips at the side edges of the structure as shown in Fig. 1 and preferably with the adjoining edges of the adja.- cent strips overlapping slightly. Then the s trips 17 and are fastened together at the end of the set and at spaced intervals longitudinally of the set by suitable fastening means securing the adjoining or overlapping parts of the several strips. In the construction shown in Fig. 1 this fastening means consists of `transversely extending rows of stitches 25 at the oppositends of the pad and transversely extending rows oil stitches 26 preierably extending from side to side of the pad at the proper intervals. The interval between the end seams 25 andthe adjay cent regular cross seams 26 or between any two of the cross` seams. 26is large enough to. allow'the largest coil which will ordinarily be either end: coil 27 of spring 10V to. be passed through the slit 13 left between the adjoining edges offany two adjacent silencingstrips. In practice as appearsy in Fig. this space between the transverse seams. will beA the same as the distance between centers of the adjoining springs, in the longitudinal row-s. Therefore, this distance may vary according to the constructionoi the'spr-ing in; that the longitudinal rows may have their springs even slightly overlap` or may be just. apartor may be; appreciably apart as shown.v in Fig. 5. In the; structure shown in Fig. I thetransverse seams and 26. extend entirely across. thestrueture. and so not only` fasten adjacent strips-.togetheron those lines but strengthen the structure byhaving the seams 25 and. 26 extend crosswise of' the strips and so strengthen the pad: and make it less liable Vto bei distorted. l Y

In the form of pad shown in Fig. 2' the same. number of full width strips 1:7 are used and of course the two half width strips23; In this structure also, preferably but not necessarily.- the ad:A

joining strips overlap. The fastening means in this structurev are wire or metal ring-1 clips. 28i of the type often used inl connecting coiled strips*` and consisting otr a U`shaped loop.v the ends. of which are passed through the adjoining strips; and' then by a proper tool having the endsbrought; together and usually overlap forming a ring .clip-l It will be seenA that these clips. 2.8 hold the strips; assembled in therpadat the necessary points: on adjoining strips but do not. directly otherwise strengthen the general structurev of the pad. It. will be understood that the rings 23.'` willl extendin a rowl across both ends of the pad and. also will extend in transverse rows acrossy the pad as shown in Fig; 2 assuming that the springs are arranged in transverserows as suggested in: Fig. 5.

Fig. 3 shows a further modified form ot hold#l ing the proper number of strips assernhled:A into: a silencing pad. In this con-struction' narrow but strong bands 29 of cloth arearranged trans;

- versely of the set 'of strips, one band 29 at spaced.

intervals similar to the intermediate transverse rows of stitches 26 in Fig'. 1-. The end bandsa're fastened as by sewing or clips to each silencingY strip and the intermediatebandsarei? tened tothe edge or narrownai-ffwidtn suene-zi strips' z3 and to more or less or the intervening middle-strips. preferably at adjoining edges thereof according to the requirements ofthe structure. `In'otharwords,` by asteningthese bands of cloth tol the; silencing strips at each meeting point of' the bands a very strong structure will be obtained especially as it will be understood that the bands 29 are in pairs, one of each pair being at the top of the structure and one at the bottom. For some structures it is found that it is not necessary to fasten together the two bands of a pair at ever-y intersection of adjoining edges of the silencing Strips.; i

In all forms of the pad it will be seen that slits 13 are left along each adjoining pair of silencing strips between adjoining and transverse seams or other transverse fastening ineinbers. There will be a slit for each coiled spring 41 01 of the set of springflling. In the structure shown Fig. 5 the slits 13 will besornewhat longer'. than. the diameter of the largest coil of the spring which will ordinarily be either end coil of thevspring'. In the structure shown in Figs.J lr and 2 the slits are shown as only about the length of the diameter of the springs. It will be understood that. the slits. 113 `are of: a. length sum'cientto allow the largesticoil of thehalf of the proper spring to be passed therethrough. The sli-tinay beA somewhatless; than the diameter of the spring, but still allowy the largest coil of the spring to. be passedtherethrough either by temporarily stretching thefabrioslightly. or bydistorting temporarilyy the end coil' oli thejspr-ing. It be understood that the pad' is mounted upon the set, of springs by so passing-.the largest coil or vend coil 27 of the spring through` theel-it 13 and then working the pad down onto the spring until it reaches` about the middle'of the; vertical orliongittudi'nal' height. of' the coiled spring more or less. as shown ini Fig. 6; In practice the set of coiled springs I0. arev arranged in rows longitudinally andf also usually in rows transversely and are then fastened together ati-one surface of thevr setv say the bottom surface by suitable means 11. connecting the adjoining springs in each lungitudinal row and the adjoining Springs in transverse rows. In thestructure shown? in Figs. 5` and 6' the` fastening means. 1l consists ci a spiral wire which is of a proper diameter in. its. coil to be screwed about two: springs: oppositeeaoh other in.

the transverse row and then to extend on to be sorewedi'through two similarly adjoining Springs inthe..Y next transverse row: of: Springs but farther alongin the two longitudinal rows- This spiral Wire accordingly answers both purposes of; fasten;` ing in adjoining springslirl-` transverse. rows and; alsoy connecting the springs in longitudinal rows. It wil-L be understood. hmm/ver, that the means of' fastening, the; springs longitudinal andtransverse rows may vary ,and any particular meensis not essential to` this, invention.V

Assuming-l the set, oiisprings tok be. so; fastened together at one surface, Say the bottom surface, and with the end coils 2'7 at the other ortop. sur-fateci the set. of` springs. to, be still unconnected the: had l2. will be placed on top of the setoi springs` and the padthen worked. down half way through the Vertical height. of the. Springs. by temporarily,v and successively opening un the respective slits.- so. as to. nass thetop half of eachspring. up throughv itslooen slit. After they top o'rlarger` coil has. beenjpassed .through its slitthe Dad may be. more'. easily worked, down into, its permanent. position; about midway the verticalhejeht oithesnrng.- f After altra-ris of l.

thepadfhave thus been located' about midway oi thel height of the set vofv springs it: will `be. seen that the pad willire-adjust itself' moreor lessr invaso? spring will have a portion of the'silencing pad located substantially horizontally of the cushion midway the height of the spring. At the point where the pad is so located upon the middle oi the spring one of the middle coils as 30 will pass through the slit at that spot slightly distorting the even arrangement of the two adjacent silencing strips. Beyond this passing point, however,- one-half of the said middle coil 30 will'be iinmediately above the one silencing strip and the other part of the coil will be immediately below the other .silencing strip forming the slit.l lt will be thus seen that whichever surface of the cushion is turned up there will be a supporting coil of the spring to hold the pad in place. VThis holding of the pad in place will be further regulated and strengthened by the fact that any great distortion or slipping of any part of the silencing pad is prevented by the rest of the pad through its engagement with other coil springs tending to hold it in place. After the silencing pad is thus mounted upon the set of springs the other or upper surfaces of the springs are fastened together by suitable fastening means 11 connecting adjoining springs in the transverse rows and connecting adjoining springs in the longitudinal rows. In the construction shown in Fig. 5 the fastening means consists of the spiral wire already mentioned. After the set of springs have thus had their other surface connected the silencing pad cannot be removed without destroying the pad or removing one set of fastening means of the set of springs. On the other hand. it will be seen that no separate fastening means have to be provided to hold the pad in position upon the springs.

It will be understood that in these spring cushion constructions it is very common to use coiled springs of the hour-glass type, partly because such springs give a soft yielding action to both surfaces of the cushion followed by greater strength as the intermediate smaller coils are brought into play and partly because the decreasing spiral form of each half of the spring prevents adjacent coils touching each other and mak- Vseveral coiled springs of the cushion prevents this direct noise-producing contact of similar sized coils of opposite halves of the respective springs. In fact, my construction prevents direct contact of any coil of one half of a spring with any coil of the other half of the same spring or with any coil of an adjacent spring on the other side of the pad both of which classes of contacts may happen when the springs are subjected to lateral distortion as well as compression.

My pad provides not only a suliicient body of brous filling or packing to hold the coils from noisy engagement but also provides a fabric covering on each surface of the packing to hold the packing securely and permanently in place and take the initial Contact of the coils of the springs which would otherwise tend to soon push the iibrous illing away from the engaging points.

The seams of stitches in the pad at opposite sides of each slit and extending lengthwise of the silencing strips aided by the crosswise stitches or otherl fastening means used at the ends of the slits operate to permanently hold the lling in place inthe pad.

Fig. 9 is a top or bottom view of a modified form of silencing pad. This pad 12a is formed of three layers of material, viz: two layers of fabric en- Iclosing a lling of iibrous material but the sheets of fabric 15a and -16a and the'sheets of brous :iilling 14a arethe'full size of the ultimate pad 12a. Besides the end seams 31 and the side seams 32, there are as many pairs of 'longitudinally extending rows of stitches 33 as there-'are longitudinal rows of springs inthe cushion and a' pair of these closely arrangedseainsSS are locatedto be ODDQ` site the vertical` center ofeaoh longitudinal row of springs. These various'row's of stitches securely fasten together the -`three layers of the pad; rlhen slits 34 are cut between the rows of stitches 33 of each pair of these rows to correspond with each spring of the cushion, such slits extending entirely through the Ythickness of the pad.

Fig. 10 shows a further modication of the pad. This pad 12b is adapted for use upon a chair seat or a sofa seat where the springs are more or less staggered, that is not arranged in regular longitudinal and transverse rows but intertted. Fig. 10 is a plan View of a pad 12b of a size for use with a chair seat wherein the set of five springs are arranged one in each corner and the fifth in the middle of the seat and not in a longitudinal row nor a transverse row with any of the other four springs. This pad is formed of two silencing strips 35 having a width of about two-thirds the diameter of the springs and two side silencing strips 36 having a width of slightly more than half the diameter of the springs. In addition to the end seams 37 and the side seams 38, there are two transverse seams 39. These seams 39, however, do not extend straight across but are reversely curved iirst at 40 to go around the inner sides of the corner springs and then at 41 to go around the two outer sides of the inside spring. This forms nine slits in all between the adjacent edges of adjoining strips but only the ve slits 42 corresponding to the five springs are used and the four shorter slits 43, one at the middle of each side, are not occupied by a spring.

What I claim as new and desire to secure by Letters Patent is:

l. in combination a set of coiled springs arranged side loy side in rows and having their adjacent end coils connected and a silencer pad comprising strips of sound-deadening material arranged intermediate the length of the springs andthe separate strips extending from the middle of the springs of one row to the middle of the springs of an adjacent row, means fastening the edges of adjacent silencer strips together between adjacent springs of each row and at the ends of the strips whereby slits between adjacent strips are left for each spring whereby an intermediate coil of each spring may project through its slit and the material of the silencer strip on one side of the slit will be above the said intermediate coil and the strip on the other side of the slit will be below said coil.

2. In combination a set of coiled springs arranged side by side in rows and having their adjacent end coils connected and a silencer pad comprising strips of iibrous packing secured between 'l fabric layers arranged intermediate the length of the springs and the separate strips extending from the middle of the springs of one row to the middle of the springs of an adjacent row, means fastening the edges of adjacent silencer strips togetherbetween adjacent springs of each row and at the ends of the strips whereby slits between adjacent strips are left for each spring whereby an intermediate coil of each spring may project through its slit and the material of the silencer strip on one side of the slit will be above the said intermediate coil and the strip on the other side of the slit will be below said coil.

Y 3. VA silencer pad for use .with a set of cushion side by side but leaving an open slit for each spring between adjacent strips through which slit an end of a spring may be inserted.

Li. A silencer pad for use with a set of cushion springs arranged in rows and to be placed intemnediatev the ends of the springs, consisting of a plurality of strips of brous padding secured between fabric layers and arranged side by side, the main strips being of a width to reach from the center of the springs of one row to the center of the springs of an adjacent row and half-Width strips at the sides of the pad and means holding said strips loosely side by side but leavingran open slit for each spring, between adjacent strips through which slit an end of a spring may be inserted.

y WILLIAM B. FOSTER. 

